Stacked Magnetic-Component Module for Compact Transformer Isolation
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Solution Overview
Problem
There is a need for smaller, more efficient, and lower-cost transformers that operate with reduced power consumption, particularly in applications such as telecommunications, implantable medical devices, and battery-operated wireless devices.
Innovation Solution
A magnetic-component module design featuring a substrate with a disc-shaped and cylinder-shaped header supporting a core, windings defined by traces, and wire bonds, encapsulated by overmold material, with optional stacking of headers and use of standoffs for electrical connection to a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional adjacent coil arrangement is used, then transformer functionality is achieved, but component size is large
Solution Approach 1:
The patent transitions from traditional planar adjacent coil arrangement to a three-dimensional stacked configuration where multiple headers are vertically positioned around a central core. This dimensional change allows compact integration while maintaining electrical isolation and magnetic coupling, effectively reducing the transformer footprint without excessive complexity
Solution Approach 2:
Multiple headers containing windings are nested in a stacked arrangement around a central magnetic core. The headers are positioned at different heights (e.g., first header at first height, second header at second height), creating a nested cylindrical configuration that maximizes space utilization and reduces overall component volume
2Use of energy by moving object
If transformer size is reduced, then power consumption is reduced, but manufacturing cost increases
Solution Approach 1:
The header structure serves multiple functions simultaneously: it provides mechanical support for the windings, establishes electrical connections through integrated traces, provides structural framework for the stacked configuration, and enables mounting to substrates. This multi-functionality reduces the need for separate components, simplifying manufacturing despite the compact three-dimensional design
Solution Approach 2:
The patent combines multiple functional elements into integrated headers that include both structural support features and electrical trace patterns. The headers merge mechanical and electrical functions, reducing assembly steps and manufacturing complexity while achieving compact transformer dimensions for reduced power consumption applications
3Volume of moving object
If headers are stacked in three dimensions, then transformer size is minimized, but electrical connection complexity increases
Solution Approach 1:
The patent resolves connection complexity by utilizing the vertical dimension for electrical connections between stacked headers. Wire bonds or conductive structures extend vertically between headers at different heights, transforming what would be complex lateral connections into simpler vertical connections, thereby maintaining compact size while managing connection complexity
Solution Approach 2:
The magnetic core serves as a central intermediary structure around which multiple headers are stacked. This central core provides a reference framework that simplifies the spatial arrangement and electrical connections between headers, as all connections can be referenced to the central core position, reducing overall connection complexity despite the three-dimensional stacked configuration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves compact size, high efficiency, and cost-effectiveness, enabling transformers with improved power management and isolation capabilities, suitable for various applications including industrial, medical, and automotive uses.
Implementation Method 1
The primary winding(s) receive electrical energy, such as from a power source, and couples this energy to the secondary winding(s) by a changing magnetic field. The energy appears as an electromagnetic force across the secondary winding(s).
Data Source
AI summary
A magnetic-component module includes a first header, a core on the first header, and a winding including a first trace on the first header. The first header includes a disc-shaped portion that supports the core and a cylinder-shaped portion that receives a hole of the core.